Toaster with controlled conveyor speed

ABSTRACT

A method of operating an oven to cook a food product that includes changing a heat setting of a heating element of the oven, selecting a cook time for the food product in the oven, driving a heating element of the oven at a heat power input based on the heat setting, predicting a cooking ability of the oven by calculating an estimated temperature in the oven using a formula that is a function of a heat power input during a previous time period, and modifying the cook time to a modified cook time based on the estimated temperature that was calculated using the formula.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/473,285, filed May 16, 2012, the entire contents of which are herebyincorporated by reference herein.

BACKGROUND

The present invention relates to the field of conveyor toasters, andspecifically to mechanisms for controlling the degree of cooking of thefood product.

Conveyor toasters typically include a housing having a cook chamber, aconveyor for moving food product through the cook chamber, and heatingelements for cooking the food product as it is moved through the cookchamber. In order to control the level of cooking of the food product,it is known to control the speed of the conveyor. For example, U.S. Pat.No. 6,624,396, assigned to Hatco Corporation discloses a conveyor oventhat controls the speed of the conveyor based on the temperature insidethe oven. For example, if the temperature in the oven is relatively low,then the conveyor will slow down to allow the food product to cook tothe desired level. In addition, U.S. Pat. No. 5,253,564 discloses aconveyor oven that has pre-programmed cook options with differentconveyor speeds and heat percentage for different types of foodproducts.

In order to conserve energy, conveyor toasters often include a standbymode that stops the conveyor and reduces the heat percentage supplied tothe heating elements. The standby mode can be entered by pressing anappropriate button (e.g., a “standby” button), or it can be enteredautomatically upon the detection of no food product on the conveyor fora period of time. The standby mode can be exited by pressing anappropriate button (e.g., a “cook” button), or it can be exitedautomatically upon the detection of food product on the conveyor.

SUMMARY

The present invention provides a conveyor oven comprising a housingdefining a cook chamber and a heating element positioned adjacent thecook chamber. A controller is programmed to control a cook time basedupon a current estimated temperature in the oven, wherein the currentestimated temperature is a function of a heat power input during aprevious time period. Preferably, the oven further includes a conveyorpositioned to move food product through the cook chamber, and a motorcoupled to the conveyor, wherein the controller is programmed to controla speed of the conveyor. In one embodiment, the current estimatedtemperature is a function of a previous estimated temperature. Anelement time constant can be used to account for different ovens.

In another aspect of the invention, the controller is programmed tocontrol a cook time based upon a product load calculation, wherein theproduct load calculation is a function of a presence of food in theoven. In one embodiment, the oven further includes a presence sensor fordetecting the presence of food in the oven and providing a correspondingsignal to the controller. Preferably, the product load calculation is afunction of a previous product load calculation, with or without acorresponding time constant.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an oven embodying the present invention.

FIG. 2 is a section view taken along line 2-2 in FIG. 1.

FIG. 3 is a section view taken along line 3-3 in FIG. 1.

FIG. 4 is a chart showing heat-based speed modification.

FIG. 5 is a chart showing product-based speed compensation.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass both direct and indirectmountings, connections, supports, and couplings. Further, “connected”and “coupled” are not restricted to physical or mechanical connectionsor couplings.

FIG. 1 illustrates a conveyor toaster 10 that embodies the presentinvention. The toaster includes a housing 12 defining a cook chamber 14,top and bottom heating elements 15,16 positioned adjacent the cookchamber 14, and a conveyor 18 positioned to move food product throughthe cook chamber 14. A motor 22 is coupled to the conveyor 18 to providemovement to the conveyor 18. The cook chamber 14 has an entrance 24through which a food product enters the toaster 10 and an exit 26through which the food product exits the toaster 10 after the foodproduct is cooked. A user input 28 can be used to input information intothe toaster 10. A controller 30 is programmed to control the heatingelement 15,16 and a speed of the conveyor 18 based upon the user inputand a variety of parameters and conditions.

The controller is programmed to operate the toaster in one of severaldifferent modes corresponding with different food types (e.g., bread,bagels, frozen waffles, etc.) that should be cooked at different heatsettings and different cook times. The user can input the appropriatefood type into the user input. Each food type will have a programmeddesired heat setting HS and desired cook time CT that are pre-programmedbased upon the steady-state characteristics of the toaster. Unlessotherwise noted, the heat setting HS is presented as a dimensionlessnumber from zero to 100. For example, a heat setting of 25 means thatthe corresponding heating element should be operating at 25% capacity atsteady state, and a heat setting of 100 means that the heating elementshould be operating at its maximum or 100% capacity at steady state. Thecook time CT is presented as the amount of time (e.g., in seconds) thata product takes to get through the toaster. For example, a cook time CTof 45 means that a product traveling on the belt has a throughput timeof 45 seconds. For toasters with conveyors, the cook time will beinversely proportional to the conveyor speed. For toasters that do nothave a conveyor, the cook time can be the amount of time for a cookcycle, which can be controlled by an alarm or by pushing the food out ofthe oven at the end of the cook time. For example, for a drawer-typeoven, the drawer can pop open at the end of the cook time.

The controller drives the heating elements at a heat power input (e.g.,the power provided to the heating elements), which can be represented bya heat percentage HP. The heat percentage HP is a dimensionless numberfrom zero to 100 that represents the actual power level provided to thecorresponding heating element. For example, an upper heat percentage HPof 65 means that the upper heating element is driven at 65% of its ratedwattage. At steady state, the heat percentage HP of a heating elementshould approximately correspond with the heat setting HS for thatheating element. However, when changing a heat setting, it is oftendesired to provide a heat percentage HP that is beyond (i.e., above whenincreasing the temperature and below when decreasing the temperature)the targeted heat setting in order to facilitate a faster change in thecooking ability of the oven. For example, when changing from a heatsetting of 40 to a heat setting of 75, the controller can be programmedto drive the corresponding heating element at a heat percentage HP of 90for a short period of time in order to bring the oven up to the desiredcooking ability more quickly.

The heat percentage HP is calculated every second according to thefollowing formula:

HP=(HS+(proportional gain*(HS−ET)

-   -   HS=heat setting    -   Proportional gain=2.0    -   ET=estimated temperature (defined below)        The proportional gain is a dimensionless multiplier that        determines the rate at which the toaster will be heated or        cooled when changing the heat settings. A larger proportional        gain will heat and cool for rapidly, and a smaller gain will        heat and cool more slowly. If the calculated heat percentage is        greater than 100, then the actual heat percentage will be 100.        Also, if the calculated heat percentage is less than zero, then        the actual heat percentage will be 0.

The controller is also programmed to control the speed of the conveyor18 based upon a predicted cooking ability or estimated temperature ET ofthe toaster 10. For example, if the estimated temperature ET isrelatively low, the controller 30 will decrease the speed of theconveyor 18 so that the food product can cook properly. Similarly, ifthe estimated temperature ET is relatively high, the controller 30 willincrease the speed of the conveyor 18 so that the food product does notover cook. The estimated temperature ET is a dimensionless numberbetween zero and 100 and represents a calculated estimation of theability of the toaster to cook food. An estimated temperature ET of zerocorresponds with a toaster that is turned off long enough for thetoaster to achieve a steady-state temperature. Similarly, an estimatedtemperature ET of 100 corresponds with a toaster when it has beenrunning at a maximum heat setting long enough to achieve a steady-statetemperature. The estimated temperature ET is calculated every secondaccording to the following formula:

ET=(ET _(previous) *HTC)+(HP _(previous)*(1−HTC)

-   -   ET_(previous)=ET from the previous time period    -   HTC=heat time constant    -   HP_(previous)=HP from the previous time period        The heat time constant HTC is a number from zero to one that        represents the estimated rate at which a change in element        wattage causes a change in toasting ability. The heat time        constant HTC is derived empirically from element testing and is        subject to change if there are changes to the element wattage,        size, or other variable. In the illustrated embodiment, the HTC        is 0.9952 for both the top and bottom elements when the        temperature is rising and 0.9970 for both the top and bottom        elements when the temperature is falling.

The estimated temperature ET is used to calculate a heat-based speedmodifier MOD_(heat) that will determine the desired speed of theconveyor. The heat-based speed modifier MOD_(heat) is a dimensionlessnumber from zero to 100 that represents the % of maximum conveyor speed.The heat-based speed modifier MOD_(heat) is calculated every secondaccording to the following formula:

MOD _(heat)=1+(top gain*(ET _(top) −HS _(top))/HS _(top))+(bottomgain*(ET _(bot) −HS _(bot))/HS _(bot))

-   -   top gain=1.08    -   ET_(top)=estimated temperature of the top element    -   HS_(top)=heat setting of the top element    -   bottom gain=1.08    -   ET_(bot)=estimated temperature of the bottom element    -   HS_(bot)=heat setting of the bottom element        The top gain and bottom gain are used to describe a relationship        between heat difference and necessary speed difference that is        other than 1:1.

Using the above-calculated heat-based speed modification MOD_(heat), theconveyor will be driven at a speed corresponding with an actual cooktime CT_(actual) that a modification of the setpoint cook timeCT_(setpoint) and is calculated according to the following formula:

CT _(actual) =MOD _(heat) *CT _(setpoint) *MOD _(other)

-   -   MOD_(other)=other modification

The toaster also includes a product sensor in the form of an electriceye (a transmitter 32, reflector 34, and receiver 36) that will sensewhen a product has been placed on the conveyor. The controller isprogrammed to enter a standby mode if it detects no activity (i.e., noproducts placed on the conveyor and no activity of the user input) for aperiod of time, such as fifteen minutes. When in the standby mode, theconveyor is stopped and the top and bottom heat settings are set at auser-programmable value, such as 25. In standby mode, once steady stateoperation has been achieved, the heat percentage HP of both the top andbottom heating elements is also 25, and the estimated temperature of thetop and bottom elements is 25, according to the above-noted formulas.

The chart in FIG. 4 shows heat percentage HP, estimated temperature ET,and heat-based speed modification MOD_(heat) calculated according to theabove formulas when changing from the standby mode (top and bottom heatsettings at 25) to a cooking mode have a bottom heat setting of 90 and atop heating setting of 65. In this example, the toaster is in thestandby mode from time=zero until time=60 seconds. At that point, thetop heat setting is changed from 25 to 65, and the bottom heat settingis changed from 25 to 90. Starting at time=60 seconds, the calculatedheat percentages, predicted cooking abilities, and heat-based speedmodification MOD_(heat) will change according to the formulas.

After the heat percentage HP is calculated based on the heat setting HSand the estimated temperature ET, a vertical heat shift is applied. Thisis intended to account for heat rising to the top of the toaster intimes when no product is going through the toaster. Vertical heat shiftis applied when the toaster has nearly reached full cooking ability(i.e., heat-based speed modification MOD_(heat) is close to 100) and theelectric eye has not detected a product for 120 seconds. Once theseconditions are satisfied, the duty cycle of the top heating elementdrops by 2% every 80 seconds up to a maximum of 8%. If desired, thebottom heating element can also be modified duty cycle using a similarmethod. It should be appreciated that the above numbers are merelyexamples, and different numbers could be used without departing from thedescribed concepts.

The controller is also programmed to adjust the conveyor speed toaccount for a product loading condition (i.e., the amount of productplaced on the conveyor over a previous period of time). If a largenumber of products are placed on the conveyor, then the actual cookingability of the toaster is less. In this regard, the controller monitorsthe data from the product sensor and calculates a product loadingmodification to the speed of the conveyor to account for the amount ofproduct on the conveyor over a previous time period. In the illustratedembodiment, the product sensor is the electric eye that determines thepresence or absence of a food product on the conveyor. Alternatively,the product sensor could be any suitable sensor, such as a mechanicalswitch. The signal from the electric eye is “0” when the eye is closed(i.e., product is present) and is “1” when the eye is open (i.e., noproduct is present).

To account for the readings from the electric eye, the controllercalculates product loading calculation called an “eye calculation” EC.The eye calculation EC is a dimensionless number from zero to one and iscalculated every second according to the following formula:

EC=(EC _(previous) *ETC)+(Reading*(1−ETC)

-   -   EC_(previous)=previous eye compensation    -   ETC=eye time constant    -   Reading=electric eye reading (“0” or “1”)

The eye time constant is a number that predicts how much toastingability a piece of food product will remove from the chamber, and issubject to change based on the product being cooked. In the illustratedembodiment, the eye time constant is 0.98. The lower boundary LB is thelowest level to which the speed will drop which being continuouslyloaded with products, and is subject to change based on the productbeing cooked. In the illustrated embodiment, the lower boundary is 0.65.

After the eye calculation EC is performed, the controller calculates aneye-based speed modifier MOD_(eye) that will be used to modify the speedof the conveyor. The eye-based speed modifier is a dimensionless numberbetween zero and one and is calculated according to the followingformula:

MOD _(eye) =EC*(1−LB)+LB

-   -   LB=Lower Boundary of Eye

Using the above-calculated eye-based speed modification MOD_(eye), theconveyor will be driven at a speed corresponding with an actual cooktime CT_(actual) that is calculated according to the following formula:

CT _(actual) =MOD _(eye) *CT _(setpoint) *MOD _(other)

The chart in FIG. 5 shows eye calculation EC and eye-based speedmodification MOD_(eye) calculated according to the above formulas undera changing signal from the electric eye. Specifically, at time=zero, theeye is open (“1”), indicating that no product is present on theconveyor. At time=60 seconds, the eye is closed (“0”) and held closeduntil time=360 seconds, at which time the eye is open for the remainderof the data.

Various features and advantages of the invention are set forth in thefollowing claims.

What is claimed is:
 1. A method of operating an oven to cook a foodproduct, the method comprising: changing a heat setting of a heatingelement of the oven; selecting a cook time for the food product in theoven; driving a heating element of the oven at a heat power input basedon the heat setting; predicting a cooking ability of the oven bycalculating an estimated temperature in the oven using a formula that isa function of a heat power input during a previous time period; andmodifying the cook time to a modified cook time based on the estimatedtemperature that was calculated using the formula.
 2. The method ofclaim 1, wherein calculating the estimated temperature in the ovenincludes using the formula that is also a function of an estimatedtemperature in the oven during a previous time period that wascalculated using the formula.
 3. The method of claim 2, whereincalculating the estimated temperature in the oven includes using theformula that is also a function of a heat time constant that representsan estimated rate at which a change in the heat setting causes a changein cooking ability.
 4. The method of claim 1, wherein selecting a cooktime includes setting a desired speed of a conveyor.
 5. The method ofclaim 4, wherein modifying the cook time includes changing the desiredspeed of the conveyor.
 6. The method of claim 4, wherein modifying thecook time includes decreasing the speed of the conveyor to increase cooktime and increasing the speed of the conveyor to decrease cook time. 7.The method of claim 1, wherein the heat power input is calculated usinga formula that is a function of the heat setting and the estimatedtemperature.
 8. The method of claim 1, further comprising modifying theheat power input based on the estimated temperature; and driving theheating element at a modified heat power input.
 9. The method of claim1, wherein the heat setting is determined based on the food product. 10.An oven operable to cook a food product, the oven comprising: a housingincluding a cook chamber; a heating element adjacent the cook chamber; acontroller in communication with the heating element to control a heatpower input to the heating element, wherein the controller is programmedto predict a cooking ability of the oven by calculating an estimatedtemperature in the cook chamber using a formula that is a function of aheat power input to the heating element during a previous time period,and wherein the controller is programmed to modify a cook time of thefood product in the cook chamber based on the estimated temperature thatwas calculated by the controller.
 11. The oven of claim 10, furthercomprising a conveyor that moves the food product through the cookchamber, wherein the controller is in communication with the conveyor tocontrol operation of the conveyor, and wherein the controller modifiesthe cook time by changing a speed of the conveyor.
 12. The oven of claim11, wherein the controller decreases the speed of the conveyor toincrease the cook time and the controller increases the speed of theconveyor to decrease cook time.
 13. The oven of claim 10, wherein theformula is also a function of an estimated temperature in the ovenduring a pervious time period that was calculated using the formula. 14.The oven of claim 13, wherein the formula is also a function a heat timeconstant that represents an estimated rate at which a change in a heatsetting causes a change in cooking ability.
 15. The oven of claim 10,wherein the controller calculates the heat power input percentage usinga formula that is a function of a heat setting and the estimatedtemperature.
 16. The oven of claim 10, wherein the controller modifiesthe heat power input based on the estimated temperature and thecontroller drives the heating element at the modified heat power input.17. The oven of claim 10, wherein the controller includes an input thatreceives information from a user related to the food product.